-
Operation andMaintenance Manual for
Hale Booster PumpsAP
CBP2CBP
Hale Products cannot assume responsibility for product failure
resulting from improper maintenance or operation. Hale Products is
responsible only to the limits stated in the product warranty.
Product specifications contained in this material are subject to
change without notice.
HALE PRODUCTS, INC. A Unit of IDEX Corporation 700 Spring Mill
Avenue Conshohocken, PA 19428 TEL: 610-825-6300 FAX: 610-825-6440
MANUAL P/N 029-0020-69-0, REV B, 2002 HALE PRODUCTS, INC., MANUAL
P/N 029-0020-53-0, REV A
ECO NO REV CHANGED FROM BY DATE APVD 02-0301 A RELEASED SAG
10/15/02 MAL
HALE PRODUCTS, INC
A Unit of IDEX Corporation Conshohocken, PA 19428 USA
DRAWN BY: SAG ISSUE DATE: CHECKED BY: PRW 10/15/02
COPYRIGHT NOT TO BE REPRODUCED OR USED TO
MAKE OTHER DRAWINGS OR MACHINERY
9615
-
Booster
i
ContentsSECTION I: INTRODUCTION
....................................................................
I-1Overview.............................................................................................................................................................
I-1
Principals Of Operation
.........................................................................................................................
I-1Centrifugal Force
..................................................................................................................................
I-1Pump Stages
........................................................................................................................................
I-2Two-Stage Booster Pump
.....................................................................................................................
I-3
Components of a Booster Pump
........................................................................................................................
I-3Pump
Body...........................................................................................................................................
I-3Impeller and Shaft Assembly
................................................................................................................
I-3 Mechanical Seal
..................................................................................................................................
I-4Gearbox
................................................................................................................................................
I-4Pump Drives
.........................................................................................................................................
I-4
Accessories
.......................................................................................................................................................
I-5Auxiliary Cooling (Overheat Protection)
................................................................................................
I-5Priming Systems
..................................................................................................................................
I-5Priming the Pump
.................................................................................................................................
I-5Priming Valves
......................................................................................................................................
I-6 Pressure Control
..................................................................................................................................
I-6Thermal Relief Valveb (TRV)
..................................................................................................................
I-7Anodes
.................................................................................................................................................
I-7
Explanation of Terms
.........................................................................................................................................
I-8
SECTION II OPERATING
PROCEDURES................................................2-1Stationary
Pumping Operations
........................................................................................................................
2-1
Pumping From a Hydrant(General Operation)
.......................................................................................................................
2-1
Draft limiting factors
.............................................................................................................................
2-2Pumping from Draft
..............................................................................................................................
2-2
Pump and Roll Operation
..................................................................................................................................
2-4Relief Valve Procedures
....................................................................................................................................
2-4
TPM /P35 Relief Valve Procedures
....................................................................................................
2-4Process of Cavitation
........................................................................................................................................
2-5
Warning Signs of Cavitation: Discharge and Gauges
..........................................................................
2-6Discharge Pressure
.............................................................................................................................
2-6Vacuum Compound Gauge
..................................................................................................................
2-6How to Prevent Cavitation
....................................................................................................................
2-6During Operations:
...............................................................................................................................
2-6Preventive Measures:
...........................................................................................................................
2-6
Post Operation procedure
.................................................................................................................................
2-8
SECTION III PREVENTIVE MAINTENANCE
............................................3-1Overview............................................................................................................................................................
3-1Post-Operation Maintenance Procedures
.........................................................................................................
3-1Weekly Maintenance
........................................................................................................................................
3-1
Relief Valve Testing
..............................................................................................................................
3-1Valve Maintenance
...............................................................................................................................
3-2Verify all Gauges are in Working Order.
...............................................................................................
3-2Inspect Water and Foam Tanks.
..........................................................................................................
3-2
Monthly Maintenance
.......................................................................................................................................
3-3Gearbox Lubrication
.............................................................................................................................
3-3Priming System Test (Dry Vacuum Test)
(Refer to NFPA 1901 or NFPA 1911)
..............................................................................................
3-3Annual Pump Maintenance
...............................................................................................................................
3-4
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Booster
ii
Replace Gearbox Oil
...........................................................................................................................
3-4Tank to Pump Flow Rate Test
..............................................................................................................
3-4Performance Testing Overview
.............................................................................................................
3-5Worn Clearance Rings and Impeller Hubs
...........................................................................................
3-8
Extreme Conditions Maintenance Guidelines
...................................................................................................
3-8
SECTION IV: TROUBLESHOOTING
.......................................................4-1SECTION V
MAINTENANCE AND
REPAIR...............................................5-1Overview............................................................................................................................................................
5-1General Repair Guidelines
................................................................................................................................
5-1
Cleaning and Inspection Guidelines
.....................................................................................................
5-1Recommended
Cleaners......................................................................................................................
5-3
Pump Components
...........................................................................................................................................
5-3Pump and Gearbox Assembly
.............................................................................................................
5-3Remove the Pump from the Apparatus
.................................................................................................
5-3AP Pump Disassembly
.......................................................................................................................
5-5AP Pump
Body....................................................................................................................................
5-5Remove AP Pump Body
......................................................................................................................
5-5Install the Pump body
..........................................................................................................................
5-5AP IMPELLER AND MECHANICAL SEAL
..........................................................................................
5-5Remove AP Impeller
.............................................................................................................................
5-5Remove AP Mechanical Seal
..............................................................................................................
5-6Reinstall AP Mechanical Seal
..............................................................................................................
5-6Reinstall the AP Impeller
......................................................................................................................
5-6REMOVE AP PUMP
HEAD.................................................................................................................
5-6REINSTALL AP PUMP
HEAD..............................................................................................................
5-7AP Gearbox
.........................................................................................................................................
5-8Disassemble AP Gearbox
....................................................................................................................
5-8Reassemble and Reinstall AP Gearbox
...............................................................................................
5-8
CBP Pump Repair
...........................................................................................................................................
5-11CBP Pump Body
................................................................................................................................
5-11Remove CBP Pump
Body...................................................................................................................
5-11 Reinstall CBP Pump Body
................................................................................................................
5-11CBP IMPELLER AND MECHANICAL SEAL
.......................................................................................
5-11Remove CBP Impeller
.........................................................................................................................
5-11Reinstall CBP Impeller
.......................................................................................................................
5-12REMOVE CBP MECHANICAL SEAL
................................................................................................
5-12Reinstall CBP Mechanical Seal
........................................................................................................
5-12CBP PUMP HEAD
............................................................................................................................
5-12REMOVE CBP PUMP HEAD
............................................................................................................
5-12Reinstall CBP Pump
Head.................................................................................................................
5-13CBP
GEARBOX.................................................................................................................................
5-13Remove and Disassemble CBP
Gearbox...........................................................................................
5-13Reassemble and Reinstall CBP Gearbox
..........................................................................................
5-14
2CBP Pump Repair
........................................................................................................................................
5-16Disassemble the 2CBP Pump from the Gearbox Assembly
............................................................
5-16Reassemble Pump to Gearbox
..........................................................................................................
5-16Disassemble the 2CBP Gearbox
.......................................................................................................
5-18Reassemble and Reinstall 2CBP Gearbox
........................................................................................
5-19
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Booster
iii
SECTION VI: PARTS LISTS
......................................................................6-1AP
Pump
.............................................................................................................................................
6-2CBP Pump
...........................................................................................................................................
6-52CBP Pump
.........................................................................................................................................
6-8Hydraulic Adapter
...........................................................................................................................................
6-12Tachometer
Option..........................................................................................................................................
6-13
-
Introduction Sec I-1
Booster Pumps
SECTION I:INTRODUCTIONOVERVIEW
Hale Products currently has 3 models of boosterpumps in
production:
o APo CBPo 2CBP
Unless otherwise indicated, these procedureswill apply to all
models of Hale booster pumps:Any variations in operations and
maintenance ofthe different models will be addressed within
thecontext of this manual.
Hale booster pumps are the favorite of firefighters throughout
the world. Booster pumpscan be used as initial attack pumps or
asauxiliary pumps in conjunction with theapparatus main pump.
Covering a range ofcapacities from 20 Gallons Per Minute (GPM)(76
Liters per Minute, LPM) to 500 GPM (1,893LPM), Hale booster pumps
offer the versatility,dependability, reliability, and ease of
operationso necessary to effective fire fighting.
Hale Booster Pumps are of a compact size andlightweight design
for easy mounting on theapparatus chassis. The pump is coupled to
thegearbox and the apparatus builder need onlysupply the
transmission PTO (power takeoff)and connecting shaft.
Principles Of Operation
This section reviews the principles of operationof Hale booster
pumps and provides adescription of the pump components.
Centrifugal Force
Hale booster pumps are centrifugal pumps thatoperate on the
principle that centrifugal force iscreated by a rapidly spinning
disk. Figure 1-1
shows an amount of water has been placed atthe center of a disk.
The disk is rotated andthe water is thrown outward from the center
tothe edge of the disk. The velocity at which thewater travels from
the center directly relates tothe diameter of the disk and the
speed ofrotation. When water is confined in a closedcontainer (such
as the pump body), the velocityis converted to pressure; pressure
is therefore,dependant on the speed of rotation.
There are three inter-related factors thatregulate the
performance of a centrifugal pump:
o Speed (RPM): If the speed of rotationincreases with the flow
held constant, the waterpressure increases.
o Pressure: Pressure is usually measuredin pounds per square
inch (PSI) or (BAR). Ifpressure changes and speed is constant,
theflow will change inversely. That is, if pressureincreases, flow
decreases.
o Flow: Flow is usually measured in thenumber of gallons of
water per minute (GPM)or liters per minute (LPM) that a pump
candeliver when supplied from draft. If thepressure is held
constant, the flow will increasewith an increase in the speed of
rotation.
Figure 1-1: Centrifugal forcefrom a rotating disk
-
Sec I- 2 Introduction
Booster Pumps
The centrifugal pump is preferred by the fireprotection service
due to its ability to fully utilizeany positive inlet pressure,
reducing the strainon the pump.
For example, if the required discharge pressureis 120 PSI (8
BAR), and the inlet pressure is 45PSI (3 BAR), the pump must only
produce thedifference in pressure of 75 PSI (5 BAR).
Thiscontributes to low engine and pump speedswhich reduces wear on
the pump. Anotherimportant benefit is the centrifugal pump
hasbasically only two moving parts; the impellerand the shaft.
Pump Stages
The number of impellers on a common shaftdetermines the number
of pump stages. Halesingle-stage booster pumps use a singleimpeller
to develop the required volume andpressure. Two stage pumps have
two impellers
on a common shaft.
During operation water enters the suction eye ofthe impeller.
The rotating impeller vanesdevelop discharge pressure and direct
the waterto the discharge opening. The cutwater is awedge that
divides the water between the volute(pump body) and the pump
discharge.
There are three models of Hale booster pumps.(The anticipated
use determines which model isselected.) The AP and CBP booster
pumps aresingle stage and provide initial attack pumpperformance
per NFPA 1901 standards. The2CBP is a two-stage series operation
pump, isused as a high-pressure booster pump.
The available Booster Pump Models and theirflow capacities are
shown in Table 1-1.Figure 1-2: Pump Stages
Figure 1-3: Single-stage Water Flow
Model Type Capacity Pressure
AP Single-Stage High Volume Attack Pump
100 to 700 GPM (379 to 2650 LPM) NFPA1901 Rated
@250 to 500 GPM (946 to 1893 LPM)
100 to 350 PSI (7 to 24 BAR)
CBP Single-Stage High
Volume Attack/Booster Pump
50 to 400 GPM (189 to 1514 LPM) NFPA1901 Rated @250 GPM (946
LPM)
100 to 400 PSI (7 to 28 BAR)
2CBP Two-Stage High Pressure Booster
Pump
20 to 100 GPM (76 to 379 LPM)
300 to 1000 PSI (21 to 69 BAR)
Table 1-1: Booster Pump Models and Capacities
-
Introduction Sec I-3
Booster Pumps
Two-Stage Booster Pump
The Hale Two-Stage Booster Pump (2CBP)has two impellers
connected in series for high-pressure operation. The output of the
firstimpeller is supplied to the intake of the secondimpeller. This
second impeller adds additionalpressure and directs the water to
the discharge.Since the two-stage booster pump onlyoperates in
series, the final water pressure isthe inlet pressure plus the
pressure added byboth impellers. The volume of water deliveredat
the discharge, however, is the same. Figure1-4 shows the flow of
water through a Hale2CBP booster pump.
COMPONENTS OF A BOOSTER
PUMP
Booster pumps are made up of:
o Pump Bodyo Impeller and Shaft Assemblyo Mechanical Sealo
Gearbox
Figure 1-5 shows these basic parts of a Hale
booster pump. These parts are brieflydescribed in the following
section.
Pump Body
The Hale single-stage booster pump body is asingle-piece
casting. Service of the impeller,clearance rings, and mechanical
seal isaccomplished by removing the pump body fromthe pump head and
gearbox.
The pump body is constructed from fine graincast iron. For areas
where salt water iscommonly used, a bronze version of the
boosterpump is available.
Impeller and Shaft Assembly
The impeller provides velocity to the water. Theimpeller is made
of high quality bronze and ismounted on a stainless steel shaft
that isrotated by the gearbox. Water enters therotating impeller at
the intake (or eye). Thevanes guide water from the inlet to
thedischarge. Vanes curve away from the directionof rotation so
water moves toward the outeredge (see Figure 1-2). The shrouds form
thesides of the impeller and keep the water
Figure 1-4: 2-Stage waterflow (Top half of 2CBP shown only.)
Figure 1-5: Parts of the Hale Booster Pump
-
Sec I- 4 Introduction
Booster Pumps
confined to increase acceleration and pressure.
The discharging tube is widest at the pumpoutlet. The increasing
discharge path, knownas the volute, collects the fast moving water
andconverts the water's velocity into pressure.
Mechanical Seal
The mechanical seal is common to all Halebooster pumps. Shown in
figure 1-6, astationary seat is in constant contact with arotating
seal ring to prevent leakage. Thesealing diaphragm is made of a
rubberelastomer specifically designed for high-temperature
operations.
If a pump is operated without water forextended periods, or
without discharging water,it may overheat. This may damage
themechanical seal or the drive mechanism.
Gearbox
The gearbox is typically constructed of finegrain alloy cast
iron. Inside the gearbox (Figure1-5) a gear set and input drive
shaft made ofheat-treated nickel steel, transfers engine powerto
the impeller. Hale offers a variety of pumpgear ratios to
accommodate a wide range ofend-user and apparatus
manufacturerrequirements based on the pump's intendeduse,
horsepower and speed rating of the
engine, and the torque rating of thetransmission PTO.
Pump Drives
There are four common types of booster pumpdrives used on fire
fighting apparatus:
1. The most common drive is the PTO mountedon the truck
transmission or four-wheel drivetransfer case which allows for pump
and rolloperation.
2. A stand-alone drive with separate engine(auxiliary
engine).
3. The truck chassis engine crankshaft (front-engine PTO).
4. Hydraulic Motor
Hale booster pumps are built to produce thevolumes and pressures
shown on theirrespective performance curves. However, thevolumes
and pressures safely obtainable aredependent on the torque capacity
of theapparatus transmission or transfer case, powertakeoff and the
pump drive line. In most cases,the torque rating of the PTO
determinesmaximum pump performance.
The apparatus builder can give various pumpperformance spots
that will define the torquelimit of the PTO in terms of GPM and
PSI.When pumping continuously, care should betaken not to overheat
the apparatus' PTO,transmission or transfer case.
HALE Power Takeoff Pumps
Hale booster pumps are available for eitherengine rotation or
opposite engine rotation PTOoperation. Additionally, the pump can
beconfigured to discharge in a variety of positions.Since some PTOs
match engine rotation andsome turn opposite of the engine rotation,
eachpump model can be built to match the rotationof the PTO.
Figure 1-6: Mechanical Seal
-
Introduction Sec I-5
Booster Pumps
NOTE: Please refer to Hale Bulletin #886 forfurther assistance
in selecting the correctbooster pump PTO.
ACCESSORIES
In addition to the basic parts of Hale boosterpumps described
above, the following items areavailable to enhance operation:
o Cooling Systemso Priming Systemso Pressure Control Deviceso
Anodes
Auxiliary Cooling (Overheat Protection)
A cooler is available to protect the gearbox, theapparatus
engine, and the pump.
The gearbox cooler (see Figure 1-7), circulatespump water to
transfer heat from the gearbox oilto the pump discharge. It is
standard equipmenton pumps with a capacity of 750 GPM or greaterand
optional equipment on all other pumps.
Priming Systems
Priming the Pump
Priming pumps are used to evacuate air in thesuction hose and
the pump. The vacuumcreated allows atmospheric pressure to
pushwater from the static source through the suctionhose and into
the pump. Hale booster pumpsuse Rotary Vane Positive Displacement
typepumps for priming.
A priming pump draws air out of the pump bodyand discharge
piping allowing water to enter.Shown in figure 1-8, the priming
pump has arotor mounted off-center (eccentric) to thepump body
housing. The vanes in the rotorslide in grooves and are held
against the bodyhousing by centrifugal force. As a vane turnstoward
the discharge, it recedes into the rotorcompressing the air. As the
rotor continuespast the discharge, the vane advances outwardfrom
the groove and against the body housing.During this cycle, the
space between the rotorand housing case fills with air. The
vanes,acting as wipers, force air out of the discharge,creating a
vacuum inthe main pumpallowing atmosphericpressure to pushwater
into the hoseand suction side ofthe pump. ESP Priming
Pump
Figure 1-8: Rotary Vane Priming Pump
Figue 1-7. This AP pump showsthe optional gearbox cooler
(Thisoption available on CBP, and2CBP too.)
-
Sec I- 6 Introduction
Booster Pumps
The Hale ESP-seriespriming pump is anenvironmentallyfriendly
primer thatdoes not require aseparate lubricantreservoir. The
vanesand pump body areself lubricating formaintenance free
operation.
A Hale priming pump has a single control toopen the priming
valve between the boosterpump and the priming pump, and start
thepriming motor.
Priming Valves
Hale priming valves open when the primingpump is operated to
allow the air to escape fromthe pump. There are two priming
valvesavailable:
1. Hale Semi-Automatic Priming Valve forRemote Mounting (SPVR) A
hose isconnected from the SPVR to the priming tapon the booster
pump body. When the SPVRis installed, a single push-button on
theoperators panel starts the priming pumpmotor. When a vacuum is
created, theSPVR opens. Releasing the push-buttonstops the priming
pump and the SPVRcloses. Figure 1-9
2. The Hale PVG Priming Valve (Figure 1 -10) is mounted on the
pump operatorspanel. The PVG is a combination valve andswitch. When
the handle on the PVG ispulled out, the valve opens and the
switchenergizes the primer motor. Pushing thehandle de-energizes
the motor and closesthe valve.
Pressure Control
The P Series relief valve system is a bronze,variable-pressure
setting relief valve thatprevents undue pressure per the
requirementsof NFPA Standard 1901. An indicator light onthe
operator control panel signals when thevalve is open.
The P Relief Valve System
The P relief valve system consists of a panelmounted control
valve (PM) and, depending onthe pressure rating of the pump, a P30,
or P35relief valve mounted in the discharge piping andplumbed back
to the pump suction. Valveconnections are either flanged or
Victaulic tm.Both are shown in figure 1-12.
How the Relief System Works:
A bleeder line mounted in the pump dischargepressure tap
provides pressure to thediaphragm in the PM control valve.
Thehandwheel on the PM control either increasesor decreases the
spring tension on thediaphragm. The seat of the P-series relief
valveis kept closed by pump discharge pressure.
As pump pressure increases, more pressure is
Figure 1 -10: PVG Priming Valve
Figure 1 -9 : SPVR Priming Valve
-
Introduction Sec I-7
Booster Pumps
applied to the diaphragm in the PM Controlvalve. As the pressure
on the diaphragmincreases beyond the set point, the stem willmove
off its seat, allowing pump pressure topush on the piston in the
relief valve. Thepressure on the piston will cause the relief
valveseat to liftallowingexcesspressure todump back tothe
pumpsuction. Afterthe pressureequalizes, thepiston returnsto the
closedposition.
The amberindicator light on the PM control illuminateswhen the
relief valve is open.
Thermal Relief Valveb (TRV)
The Thermal Relief Valve (see Figure 1-11)protects the pump from
overheating. Theoptional TRV unit can be attached to thedischarge
piping either by flange mounting or 1-1/4" NPT threaded connection
(38 mm for theTRVM). The valve monitors the temperature ofthe water
in the pump. When the temperature
exceeds 120o F (48.9o C), the valveautomatically opens and
depending on theinstallation, discharges a small amount of
watereither to the ground or into the water tankallowing cooler
water to enter. After thetemperature returns to a safe level, the
valvecloses. The TRV will flow up to 1-2 GPM (3-7LPM).
TRV-L Kit
The TRV-L kit includes a chrome panel placardwith a warning
lamp, lamp test button, and apreassembled wiring harness. The
lightilluminates whenever the TRV is open anddischarging water. An
optional buzzer providesaudible warning. The buzzer mounts on
theoperator panel.
Anodes
The Hale Anode Systemhelps prevent damagecaused by galvanic
corrosionin the pump. Galvanic actionpits the pump and pumpshaft
material. The popularityof non-corrosive water tanksand piping has
increased thistype of corrosion in todaysfire pumps. The Hale
AnodeSystem is a sacrificial metal, which helpsprevent corrosion.
The anode will fit on anyHale truck mounted pump, regardless of age
ormodel. It is designed to be easily installedrequiring four bolts
and a gasket. Total time toinstall is just fifteen minutes, yet it
will provideyears of protection for the pump. The Anode kitis
designed for installation in the standard Hale115 series flange
opening. On fabricatedmanifolds and similar applications, the
installeris to provide 1-1/4 NPT openings and installanodes
directly. It is recommended that oneanode be installed on the
suction side and oneon the discharge side.
Figure 1-11: TRV-L
Figure 1-13:Hale Anode
Figure 1-12:
-
Sec I- 8 Introduction
Booster Pumps
EXPLANATION OF TERMS
Atmospheric Pressure
Static air pressure. Air pressure is 14 poundsper square inch at
sea level. Pressure increasesbelow sea level and decreases above
sea level.The weather also effects air pressure. Air in ahigh
pressure area compresses and warms as itdescends. The warming
inhibits the formation ofclouds, meaning the sky is normally sunny
inhigh-pressure areas. But haze and fog stillmight form. Just the
opposite occurs within anarea of low atmospheric pressure.
Atmosphericpressure effects a pumps ability to pump fromdraft.
Higher pressures will increase a pumpsperformance, while lower
pressures can causea noticeable decrease in lift.
Cavitation
The sudden formation and collapse of low-pressure bubbles in
liquids by means ofmechanical forces, such as those resulting
fromrotation of a pump impeller.
Dead Heading
Operating a pump without any discharge. Lackof flow causes
temperatures to rise inside thepump.
Impeller
The working part of centrifugal pumps whichimparts energy
(motion) to the water.Essentially, an impeller consists of two
discsseparated by curved vanes. The vanes forcethe water to rotate
between the discs and isthrown outward at high velocity. The water
fromthe impeller discharges into a divergingpassage known as a
volute, converting the highvelocity energy of the water into
pressure.
Priming Pump
An auxiliary positive displacement pump whichpumps air out of
the booster pump creating avacuum in order to prime the pump.
Thepriming pump is a rotary vane type, electricmotor driven. Once
the main pump is primedand pumping, the priming pump is shut
off.
Relief Valve
An automatic valve which, when activated bythe relief valve
control will hold the pumppressure to no more than 30 PSI when
thepump discharge is gated or closed. The valvemaintains a set
pressure by diverting the pumpdischarge flow into the pump
suction.
Relief Valve Control (PM)
A hand adjustment valve. When set to thedesired pressure, the
relief valve will maintainthe desired pump discharge pressure and
limita pressure increase to no more than 30 PSI (2BAR).
Volute
The increasing discharge path of the pump, itsfunction is to
collect the water from the impellerand depending on its design can
either increasepressure and decrease velocity or increasevelocity
and decrease pressure.
-
Operating Procedures Sec II- 1
Booster Pumps
SECTION II OPERATINGPROCEDURES
This section supplies information andprocedures for the
operation of Hale boosterpumps. Included in this section are
proceduresfor pumping from an on-board tank, a hydrant,from draft,
and post-operation procedures.
Unless otherwise indicated, these instructionsapply to all Hale
booster pumps.
THE PROCEDURES IN THIS SECTION AREGENERAL OPERATING PROCEDURES.
THEYDO NOT REPLACE LOCAL PROCEDURES ORPOLICIES, NOR DO THEY REPLACE
THERECOMMENDATIONS AND PROCEDURESPROVIDED IN THE TRUCK MANUAL.
STATIONARY PUMPING OPERATIONS
Pumping From a Hydrant(General Operation)
1. Position the truck for the best hydrant hookupand discharge
hose layout.
REFER TO DEPARTMENT PROCEDURESFOR SETTING WHEEL CHOCKS AND
LAYINGOUT SUCTION AND DISCHARGE HOSES.
ALL VALVES, DRAIN COCKS, AND CAPSSHOULD BE CLOSED.
2. Bring the truck to a complete stop beforeattempting to shift
from "road" to "pump".
3. Apply the truck parking brake.
4. Shift the truck transmission to the NEUTRALposition.
5. Engage the pump PTO switch.
DO NOT LEAVE THE CAB OR ATTEMPT TOPUMP UNTIL ALL "OK TO PUMP"
LIGHTS INTHE CAB ARE ILLUMINATED. (Figure 2-1).
6. Exit the driving compartment only after all theabove steps
are completed.
DO NOT OPEN THE THROTTLE UNLESSTHE GREEN INDICATOR LIGHT IS
ON(Figure 2-2).
7. Verify the pump panel shift indicator light ison and that all
hose connections are com-plete.
8. Open the hydrant. Bleed off the air from thesuction hose.
9. Open the suction valve.
10. If necessary to eliminate air pockets, primethe pump; see
Pumping From Draft forinstructions.
Figure 2-1: Driver's CompartmentIndicator Lights
-
Sec II- 2 Operating Procedures
Booster Pumps
11. Advance the engine throttle gradually untilthe master
discharge gauge indicates thedesired pressure.
DO NOT REDUCE THE PRESSURE ONTHE INTAKE GAUGE BELOW ZERO;SERIOUS
DAMAGE TO THE WATER MAINCOULD RESULT.
The master intake gauge reading must bemaintained at 5 PSI (.3
BAR), minimum. If thegauge shows a vacuum the pump is attemptingto
draw more water than the hydrant cansupply. When this occurs,
reduce the pump flowto increase the pressure.
As the throttle is opened, the pressure gaugereading increases
with the engine speed. If theengine speed increases without an
increase inpressure, the pump is beginning to cavitate.Close the
throttle slowly until the pressurebegins to drop, and the engine
returns to an idle.
12. Set the automatic relief valve according todepartment
policy. If no department policyexists, refer to the Relief Valve
Procedureslater in this section.
13. If the pump overheats and it is not equippedwith a Hale TRV
valve, open the valve toaccess the bypass line, if it is furnished,
oropen the valve to the booster tank (bothsuction and discharge
sides) to circulatewater.
14. After completion of pumping operations,gradually reduce the
pump pressure until theengine is at idle speed. Disengage the
PTO.
DRAFT LIMITING FACTORS
The effect of raised water temperatures whenpumping from a
positive pressure source(hydrant) is negligible on fire
pumpperformance. But when pumping from draft,elevated water
temperature does have a limitingeffect. Water temperatures above
95o F (35o C)will cause a noticeable decrease in lift whendrafting.
Another factor that can limit lift whendrafting is barometric
pressures below 29 In ofHg. It is important to be aware of
environmentalconditions when drafting.
PUMPING FROM DRAFT
1. Get as close to the water source as possible.The pump can
draw 100% of its rated capac-ity with less than a 10 foot vertical
lift. As thelift increases to above 10 feet, the pump
Water TemperatureFo (C)
Lift LossHead Ft (Meters)
60 (16) NFPA Baseline
70 (21) .3 (.09)
80 (27) .6 (.18)
90 (32) 1.1 (.335)
100 (38) 1.7 (.52)
110 (43) 2.5 (.76)
Table 2-1 : Additional Losses BeyondBaseline NFPA Rating
Figure 2-2: Pump Operator's Panel
-
Operating Procedures Sec II- 3
Booster Pumps
Running the engine at speeds higher than1200 RPM during priming
is not recom-mended since it will not improve primingoperation and
may cause damage to thepump.
IF THE DISCHARGE GAUGE READING DOESNOT INCREASE, THE INTAKE
GAUGEREADING DOES NOT FALL BELOW ZERO,OR THE PRIMING PUMP DOES
NOTDISCHARGE WATER TO THE GROUND IN 30TO 45 SECONDS, DO NOT
CONTINUE TORUN THE PRIMING PUMP. STOP THE PUMPAND CHECK FOR AIR
LEAKS OR POSSIBLEPUMP TROUBLE.
10. Gradually open the discharge valve untilwater emerges in a
steady stream. Thenopen the other discharge valves to thedesired
setting.
11. Open the engine throttle gradually until thedesired pressure
or flow is reached.
As the throttle is opened, increase the pressuregauge reading
with engine speed. If the enginespeed increases without an increase
inpressure, the pump is nearing cavitation.Cavitation will be
discussed in detail later.Reduce the flow from the pump to
maintainpressure or reduce the pressure (throttle) tomaintain
flow.
13. If a pump shutdown is desired while pumpingfrom draft,
reduce the engine speed to idle,and close the discharge valves. To
resumepumping, open the throttle and dischargevalves.
14. Set the automatic relief valve according todepartment
policy. Refer to the Relief ValveProcedures later in this
section.
15. If the pump overheats and is not equippedwith the Hale TRV
valve, open the valve toaccess the pump auxiliary cooling system,
or
capacity will be reduced.
2. Bring the truck to a complete stop.
3. Apply the truck parking brake.
4. Shift the truck transmission to the NEUTRALposition.
REFER TO DEPARTMENT PROCEDURESON SETTING WHEEL CHOCKS AND
HOSES.ALL VALVES, DRAIN COCKS, AND CAPSSHOULD BE CLOSED.
5. Engage pump PTO.
DO NOT LEAVE THE CAB OR ATTEMPTTO PUMP UNTIL ALL THE
INDICATORLIGHTS IN THE CAB ARE ON.
6. Exit the driving compartment only after all theabove steps
are completed and the indicatorlights in the cab and on the panel
are on.
DO NOT ADVANCE THE THROTTLEUNLESS THE "OK TO PUMP"
INDICATORLIGHT IS ON.
7. Verify the pump panel shift indicator light ison.
8. Activate the priming pump by pulling thecontrol handle
located on the pump panel.
9. Monitor the intake and discharge mastergauges. The pump is
primed when theintake indication reading falls below zero,and the
discharge pressure starts to in-crease. Water may also be heard
discharg-ing to the ground.
-
Sec II- 4 Operating Procedures
Booster Pumps
slightly open the drain line.
16. After completing pumping procedures,gradually reduce the
engine RPM to idlespeed and disengage the PTO.
PUMP AND ROLL OPERATION
Hale booster pumps are primarily driven by atransmission mounted
Power-Take-Off (PTO)unit.
During pump and roll operation, it is necessaryto slow the
forward motion of the apparatus tothe PTO manufacturer's
recommendedengagement speed.
The following outlines a general pump and rollprocedure:
1. Slow the apparatus to safe PTO engagementspeed as recommended
by the PTO manu-facturer.
Note: Most PTOs must be engaged while theapparatus is stopped.
Only a "Hot Shift" PTOcan be engaged while the apparatus is
rolling.
2. Engage the PTO.
3. Verify the PUMP ENGAGED light is illumi-nated.
4. Open the valve between the tank and pumpsuction.
5. Observe pump discharge pressure and verifythe pump pressure
increases.
6. Prime the pump if necessary.
7. Open the discharge valves and commenceoperations.
RELIEF VALVE PROCEDURES
TPM /P35 Relief Valve Procedures
These procedures cover the Hale TPM ReliefValve System. Be sure
to select the correctprocedure, for the equipment on the truck.
1. Set the pressure indicator on the PMDcontrol valve to a
position slightly above thenormal operating pressure (even
beforewater starts to flow).
2. After normal operating pressure has beenachieved (as
indicated on the master pres-sure gauge while the pump is
dischargingwater), slowly move the adjusting handwheel
counterclockwise until the relief valveopens, and the amber
indicator light comeson.
3. Turn the hand wheel slowly clockwise untilthe indicator light
goes out. The relief valvewill operate at the set pressure.
4. When the pump is not in operation, turn thehand wheel
clockwise back to a positionslightly above the normal operating
pressure.
Figure 2-3 PMD ReliefValve Control
-
Operating Procedures Sec II- 5
Booster Pumps
More complete and detailed information canbe found in the relief
valve manual.
THE PRESSURE INDICATOR ON THEPANEL IS ONLY A ROUGH INDICATIONOF
TPM SETTING. ALWAYS USE THEABOVE PROCEDURE TO PROPERLY SETTHE TPM
RELIEF VALVE SYSTEM.
CAVITATION
Cavitation can occur while pumping from draft,in relay, or from
a hydrant. The operator must beaware of the warning signs and
correct thesituation, or serious damage to the pump andimpeller
will occur.
Cavitation can damage the impeller and othersensitive
components, impair pumpperformance, and reduce flow capacity.
Thedamage done during any one period ofcavitation is not great, but
the effects arecumulative. Implosions occurring duringcavitation
break away or erode tiny pieces ofmetal from the internal parts and
the pumpcasing. When enough metal has been chippedaway, the
impeller becomes unbalancedcausing a strain and vibration on
bearings,bushings and shafts.
The way to eliminate cavitation is to increase theflow to the
pump, decrease the amount of waterbeing discharged from the pump,
or reduce thepressure in the pump by decreasing enginespeed.
Cavitation
Cavitation occurs when a centrifugal pump isattempting to
discharge more water than it isreceiving. It is often referred to
as the pumprunning away from the supply."
Process of Cavitation
1. When increased discharge demand exceedsthe intake, bubbles
form in the low-pressureregion (eye) of the impeller.
2. The pressure of the water in the pump dropsas it flows from
the suction flange throughthe suction nozzle and into the
impeller.
3. As flow from the pump increases, thevacuum at the impeller
increases. As thevacuum increases, the boiling point of waterin
that vacuum decreases until it reaches apoint near the impeller eye
where it boils andvaporizes.
4. Once the vapor pockets, or bubbles, enterthe impeller, the
process begins to reverseitself. As the vapor reaches the
dischargeside of the pump, it is subjected to a highpositive
pressure and condenses back to aliquid.
5. The sudden change from vapor to liquidgenerates a shock
effect that damages theimpeller and pump housing. Usually thereare
thousands of tiny vapor pockets(bubbles) rather than a few large
ones. It isthe collapsing (or implosion) of thesebubbles that
causes the characteristic soundof cavitation that has been
described asrocks tumbling in the pump.
Figure 2-4 Low Pressure Regions
-
Sec II- 6 Operating Procedures
Booster Pumps
Warning Signs of Cavitation: Dischargeand Gauges
Discharge Pressure
In a properly functioning pump, an increase inRPM will increase
the discharge pressure andvolume. An increase in engine RPM that
doesnot cause an increase in the pump dischargepressure, is the
most reliable indication that apump is approaching cavitation.
Vacuum Compound Gauge
The operator should not depend entirely on thevacuum (compound)
gauge to indicate when apump is nearing cavitation: The vacuum
gaugeis usually tapped into the intake chamberseveral inches away
from the leading edge ofthe impeller eye where the greatest amount
ofvacuum occurs. The vacuum gauge does nottake into account ambient
temperature noratmospheric pressure and is not accurate nearzero on
the vacuum scale.
How to Prevent Cavitation
A soft sleeve has an advantage over a hardsleeve when pumping
from a hydrant because itwill partially collapse providing an
immediateindication to the operator that cavitation isimminent. A
hard sleeve indicates problems onlyat the intake gauge which is not
the best or mostreliable indicator.
Monitoring current operating conditions,knowing the capabilities
of the equipment, andregular inspection are the best
protectionagainst cavitation.
During Operations:
o Do not increase the pump speed beyond thespeed at which the
pressure ceases to rise.
o Monitor the water temperature baseline perNFPA standards is 60
F (16 C). Table 2-1
illustrates the amount of lift loss astemperatures rise. If
there is a marked lossof suction capacity, the pump may be
nearcavitation.
NOTE: When water reaches 95 F( 35 C),the operator is likely to
notice a markeddecrease in lift.
o Monitor barometric pressure. NFPAstandards sets a baseline of
29.9Hg. SeeTable 2-2.
o Location: The higher the elevation abovesea level, the lower
the atmosphericpressure and less lift. See Table 2-3.
o Open the throttle gradually and watch the
pressure gauge and the tachometer, ifequipped. An increase in
engine RPMwithout a corresponding increase inpressure indicates
cavitation.
o Use a hard suction hose when pumping fromdraft and soft
suction hose when pumpingfrom hydrant.
Preventive Measures:
o Regularly inspect discharge and suctionhoses to check for air
leaks: these can also
Barometric Readingin (mb)
Lift-loss in Head Feet(meters)
29.9 (1012.53) NFPA Baselines
29.7 (1005.76) .2 (.06)
29.5 (999) .5 (.15)
29.3 (992.21) .7 (.21)
29.1 (985.444) .9 (.27)
28.9 (978.67) 1.1 (.33)
28.7 (971.89) 1.4 (.43)
Table 2-2 : Lift-Loss from Barometric Pressure
-
Operating Procedures Sec II- 7
Booster Pumps
cause cavitation.
o Consider the size of the suction hose: Table2-4 shows the NFPA
pre-selected hosesizes for each pump-rating capacity. Usingthe
appropriate-sized hose will minimize theoccurrence of
cavitation.
o Consider the piping within the truck: Furthersuction losses
may result from additionalsuction piping added to the fire pump
duringassembly by the manufacturer.
o Follow the maintenance and inspectionprocedures.
o Cavitation can occur with large nozzle tips.Solve this problem
by reducing flow.
o Cavitation can also occur when air enters thepump. The pump
may be primed, however,air leaks can cause rough operation and
anincrease of engine speed without an in-crease in pressure or
flow. If an air leak issuspected, discontinue pumping and refer
toSection IV.
ElevationFeet (Meters)
Lift-Loss in Feet(Meters)
2,000 (609) NFPA Baseline
3,000 (914) 1.1 (0.33)
4,000 (1219) 2.2 (0.67)
5,000 (1524) 3.3 (1)
6,000 (1828) 4.4 (1.34)
7,000 (2133) 5.5 (1.67)
8,000 (2438) 6.6 (2.01)
9,000 (2743) 7.7 (2.35)
10,000 (3048) 8.8 (2.68)
Table 2-3: Lift Loss from Elevation
HoseDiameters
(mm)
3"(76)
4"(102)
4 "(114)
5"(127)
6"(152)
Dual6"
FLOWS GPM(LPM) Lift Loss
250 5.2(19.7)
350 2.5(9.5)
500 5.0(19)3.6
(51.5)
750 11.4(43)8.0(30)
4.7(17.8)
1.9(7.2)
1000 14.5(55)
8.5(32)
3.4(12.9)
1250 13(49)5.2
(19.6)
1500 7.6(28.7)1.9
(7.2)
175010.4
(39.4)2.6
(9.8)
2000 3.4(12.9)
2500 5.2(19.6)
Table 2-4: Hose Sizes for Pump-Rating Capacity
-
Sec II- 8 Operating Procedures
Booster Pumps
POST OPERATION PROCEDURE
o Return the engine to idle.
o Slowly close all valves.
o Place the transmission in neutral or park.
o Slowly shift from "pump" to "road" to disen-gage the pump.
o Drain the pump (especially important infreezing weather):
a. Open the discharge valves, removesuction tube caps, and
discharge valve caps.
b. Open the pump body drain cocks or Halemultiple drain valve.
If a multiple drain valveis used, all pump drain lines should
beconnected to this valve.
c. After the pump is completely drained,replace all caps and
close all valves,
o If sea water, dirty water, alkaline wateror foam solution, has
been used, flush the pumpwith clean water.
o Remove the wheel chocks only whenpreparing to leave the
scene.
o Fill out the pump run log, indicating totalpumping time and
total out-of-station time.
o Report all pump, vehicle and equipmentmalfunctions, and
irregularities to the properauthority.
o Know and follow all local procedures.
-
Preventive Maintenance
Booster Pumps
Sec III- 1
SECTION III PREVENTIVEMAINTENANCE
OVERVIEW
Hale Booster Pumps require very little care andmaintenance.
However, the little required isimportant. Preventive maintenance
tasks takelittle time to accomplish and consist of leaktesting,
lubrication and cleaning. Theprocedures supplied in this section
are fornormal use and conditions.
This section provides recommended actions tobe completed after
each use, weekly, monthlyand annually basis.
Post-Operation Maintenance Procedures
Flush Pump
1. Inspect the suction hose and rubber washersas well as the
washers in the suction tubecaps. Remove any foreign matter from
thehose and coupling. Replace worn, dam-aged, or dry washers.
2. Verify all discharge valves, drain valves anddrain cocks are
closed.
3. Tighten the suction caps.
Weekly Maintenance
Weekly maintenance consists of:
o Testing the relief valve system
o Testing the priming system
o Testing the pump shift warning indicatorlights
o Valve Maintenance
o Checking and cleaning the intake strainers
o Checking any auxiliary engine.
o Verifying all gauges are in working order.
o Operating pump controls.
o Inspecting water and foam tanks.
o Checking roof and bumper turrets
o Checking auxiliary fire suppression equip-ment
Relief Valve Testing
When the relief valve is not in operation, keepthe hand wheel
set above the normal operatingpressure.
1. Set up to pump from theonboard water tank withthe discharge
flow back tothe water tank.
2. Turn the relief valve handwheel clockwise to thestop to
prevent the reliefvalve from operating.Figure 3-1
3. Bring the pump pressureup to 150 PSI (10 BAR) asindicated on
the masterpressure gauge pernormal operating procedures.
4. Turn the relief valve hand wheel counter-clockwise until the
relief valve opens. Therelief valve is open when the amber
indicatorlight is lit and the pressure begins to drop.
5. Turn the relief valve hand wheel clockwisethen
counterclockwise a few times to ensurethat the hand wheel turns
freely. Observethe pressure gauge and indicator light for
Figure 3-1PM Valve Control
-
Booster Pumps
Sec III- 2 Preventive Maintenance
proper valve operation.
6. Return the relief valve hand wheel and theapparatus to normal
operational condition.
Pump Shift Warning Indicator Lights
VERIFY THE PARKING BRAKE IS SET ANDTHE WHEELS ARE CHOCKED TO
PREVENTANY MOVEMENT OF THE APPARATUS.
1. Follow the operating procedures in Section IIto engage the
pump if no local proceduresexist.
2. Verify the warning indicators in the cab andthe pump control
panel function properly.
3. Verify the indicator lights on the control panelfunction
properly and agree with the indica-tors in the cab. Repair or
replace any mal-functioning indicators.
Valve Maintenance
Properly functioning valves are integral to theproper operation
of the pump. Refer to the valvemanual for proper valve
maintenanceprocedures.
1. Lubricate all suction and discharge valvesusing an approved
lubricant.
2. Verify each valve operates easily and closescompletely.
3. Inspect and lubricate all of the valve link-ages. Repair or
replace any damaged ornonfunctional linkages.
4. The relief valve operator should be lubri-cated every 5
months.
Check and Clean the Intake Strainers
Remove the strainers. Clean any debris out ofthe intake. Flush
the pump if required bydepartment procedures. Repair or replace
anydamaged strainers.
Check Auxiliary Engine
If the pump is powered by a separate engine,check the engine,
fuel tanks and drive for wearand proper operation.
Verify all Gauges are in Working Order.
Any gauge that is repeated in the cab or anotherpanel, must
agree with the gauge on theoperator's panel. Gauges not reading
within10% of the calibrated test gauge must beremoved from service
and recalibrated.
Operate Pump Controls.
Operate the pump drive controls to verify thepump can be
engaged. Verify the indicator lightswork properly.
Inspect Water and Foam Tanks.
Visually inspect water and foam tanks for properlevel and gauge
readings. If any debris ispresent, flush the tanks to protect the
pump fromwear caused by dirty water or foam concentrate.
Check Roof and Bumper Turrets
If the apparatus is so equipped, verify the turretsfunction
properly, and no leaks are present.
Check Auxiliary Fire Suppression Equipment
Visually inspect all piping and valves on thepump and auxiliary
equipment for corrosion ordamage.
-
Preventive Maintenance
Booster Pumps
Sec III- 3
Monthly Maintenance
o Check the Gearbox Oil
o Perform the dry vacuum test
o Check the drive line bolts.
Gearbox Lubrication
Too much oil or the wrong type of oil will resultin unnecessary
loss of power and high oiltemperature. Change the oil every 12
months,depending on pump usage. Recommended oilfor Hale booster
pumps is SAE EP-90, 80W-90,or synthetic 75W-80 gear oilthat meets
service rating of APIGL-5 requirements. Gearboxcapacity is one to
two quarts.
1. Remove the gearbox oil fillplug, and check the level ofthe
oil in the gearbox. Thelevel should be up to theplug hole. Figure
3-2
2. If the oil appears white or "milky," a waterleak is
indicated. Remove the drain plug(figure 3-3) and drain the oil into
a suitablecontainer. Examine the oil for metal flakes orother
contamination. Either of these condi-tions indicate maintenance is
required on theunit.
Priming System Test (Dry Vacuum Test)(Refer to NFPA 1901 or NFPA
1911)
1. Close all valves and drains. Cap all suctionopenings and the
outlet of the suction siderelief valve (if equipped).
2. Connect a test vacuumgauge or manometer to theintake test
gauge connectionon the pump panel.
3. Engage the priming pump
until the gauge indicates at least 22 IN-ngvacuum.
4. Compare the readings of the test gauge andthe apparatus
gauge. Note any difference.
5. Stop the priming pump and observe thegauge. If the vacuum
falls more than 10 in ofHg in 5 minutes, it is a certain indication
of atleast one air leak. Vacuum leaks may oftenbe detected by ear
if the apparatus engine isturned off. Correct leaks immediately
toreturn the pump to service.
6. Test the suction hose as follows:
a. Attach the suction hose to the pump.
b. Place a suction tube cap on the end ofthe hose in place of a
strainer.
c. Close all valves and drains. Cap allsuction openings and the
outlet of the suc-tion side relief valve (if so equipped).
d. Connect a calibrated vacuum gauge ormanometer to the intake
test gauge connec-tion on the pump panel.
e. Engage the priming pump until the gaugeindicates at least 22
IN-ng vacuum.
f. Watch the gauge. If the vacuum fallsmore than 10 inches in 5
minutes, it is acertain indication of at least one air leak.
g. Verify the test gauge and the apparatusgauge display the same
readings. Repair orreplace any gauges that do not display
thecorrect pressure.
IF LEAKS CANNOT BE DETECTED BYFOLLOWING THE PROCEDURE , IT
ISADVISABLE TO TEST THE PUMPHYDROSTATICALLY.
o Open all the valves.
Figure 3-2
Figure 3-3
-
Booster Pumps
Sec III- 4 Preventive Maintenance
o Place caps on all valves
o Connect a positive pressuresource
o Inspect the pump for leaks.
Drive Line and Flange Bolts
Check all drive line and flange bolts to ensure:
1. No bolts are missing.
2. All bolts are tight. Use a torque wrench totorque bolts to
the drive train manufacturer'srecommended specifications.
3. Bolts used are Grade 8 strength.
Annual Pump Maintenance
o Replace the pump gearbox oil. Use SAE EP-90, 80W-90, or
synthetic 75W-80 gear oilthat meets service rating of API GL-5
re-quirements.
o Check individual drain lines from the pump tothe multi-drain
to ensure proper drainageand protection from freezing.
o Tank to pump flow ratetest.
o Clean ESP Primer if in-stalled.
o Perform the yearly pumptest to check performancelevels. (See
NFPA Stan-dard 1911 for more details.)
Replace Gearbox Oil
1. Remove the magnetic drain plug from thegearbox.
2. Drain the oil from the gearbox.
3. Inspect the magnetic drain plug. If of metalfilings are
present on the drain plug, removethe cooler or coverplate to
visually inspectand clean the internal components. Repair orreplace
as necessary.
4. Replace the cooler or cover, if necessary.Remove the oil fill
plug, and replace the drainplug.
5. Fill the gearbox with an approved gear oiluntil the oil level
is at the fill plug opening(approximately 1 to 2 quarts).
6. Replace the fill plug.
Check Drain Lines to Multi-Drain
Drains are supplied on the pump and piping atthe lowest points
where water could collect andfreeze rendering the pump useless.
Most ofthese drains are piped together to a multi-drainto allow the
entire system to be drained by onevalve.
It is necessary to inspect each line to the multi-drain to
ensure the entire system is drainingwhen the valve is operated.
Inspect each connection and verify the individuallines to the
multi-drain are free of debris. Repairor replace any lines that are
damaged, kinked,or corroded.
Tank to Pump Flow Rate Test
Note: This procedure is written for informationonly. It does not
supercede any local proce-dure.
1. Fill the water tank until it overflows.
2. Close the tank fill line, bypass the coolingline, and all the
pump intakes.
3. Attach sufficient hoselines and nozzles toflow the desired
discharge rate.
Grade 8Bolt headFigure 3-4
Figure 3-5
-
Preventive Maintenance
Booster Pumps
Sec III- 5
4. With the pump in gear, open the discharge towhich the hose is
attached and begin flowingwater.
5. Increase the engine throttle until the maxi-mum consistent
pressure is obtained on thedischarge gauge.
6. Close the discharge valve without changingthe throttle
setting. Refill the tank through thetop fill opening or a direct
tank line. Thebypass valve may be opened during this timeto prevent
pump overheating.
7. Reopen the discharge valve, and check theflow through the
nozzle using a Pitot tube orflowmeter. Adjust the engine throttle
to bringthe pressure to the amount previouslydetermined.
8. Compare the flow rate measured to theNFPA minimum or the
designed rate of thepump. If the flow rate is lower, a
problemexists in the tank to pump line. The minimumflow rate should
be continuously dischargeduntil 80% of the tank is discharged.
The pump should experience no mechanicalproblems, powerloss, or
overheat during thetest.
Performance Testing Overview
The yearly standard performance test consistsof checking the
pump (according to the rating) atthree capacities and comparing the
results towhen the pump first placed in service. Thisprovides some
measure of any performancedeterioration. Table 3-1
A pump must be able to pump full capacity at150 PSI, 70%
capacity at 200 PSI and 50%capacity at 250 PSI.
Performance Testing Equipment andMaterials
Testing is appropriately accomplished with adead weight gauge
tester, which is usuallyavailable at the local water works.
To accurately test pumper performance,requires a Pitot gauge, a
calibrated pressuregauge, and a vacuum gauge or manometer.
Use smooth bore test nozzles of accurate sizewith the Pitot
gauge. The volume pumped isthen determined by referring to the
dischargetables for smooth nozzles. Preferably, nozzleswill be used
on a Siamese deluge gun forgreatest accuracy. A stream
straightener, justupstream of the nozzle is advisable.
Example PUMP RATING GPM (LPM)
CAPACITY PRESSUREPSI (BAR)
250(946)
350(1325)
450(1703)
500(1893)
750(2839)
1000(3785)
FULL 150 (10) 250(946)
350(1325)
450(1703)
500(1893)
750(2839)
1000(3785)
70% 200 (13) 175(662)
245(927)
315(1192)
350(1325)
525(1987)
700(2650)
50% 250 (17) 125(473)
175(662)
225(852)
250(946)
375(1419)
500(1893)
Table 3-1
-
Booster Pumps
Sec III- 6 Preventive Maintenance
Refer to local procedures for pump testingprocedures and
practices.
For Pitot gauge accuracy, the nozzle pressuresshould be between
30 and 85 PSIG. See thechart on the facing page for nozzle flow
andpressures. Table 3-3 provides GPM for variousnozzle sizes.
Because NFPA standards specify both GPMand pressure, it is
usually necessary to restrictthe flow somewhat to build up the
pumppressure. In normal pumping, this restrictionwould be caused by
the friction loss in the lines.However, depending on line loss
alone wouldrequire a large amount of hose for some tests.It is
common practice to use 50 to 100 feet ofhose and gate the discharge
valves as requiredto maintain pressure.
Performance Testing Procedure
Note: The NFPA standards require a 10 percentreserve in pressure
at the capacity run when theapparatus is delivered.
1. Check the relief valve according to the ReliefValve Testing
procedure under WeeklyMaintenance.
2. Perform steps 2 and 3 of the Post-OperationMaintenance
procedures in this section.
3. Run the standard pump test in accordancewith NFPA standards
to check pump perfor-mance.
4. Pumps rated below 750 GPM are tested foran hour per NFPA
1901, 14-13.2.3.2. Runthe engine for 20 to 30 minutes to
stabilizethe engine temperature. Then run the pumpfor 20 minutes at
capacity, 10 minutes at 70percent capacity, and 10 minutes at
50percent capacity.
5. If the apparatus does not reach performancelevels, refer to
the Diagnostic/Service chartin Section IV.
6. Compare the results of this test to those fromwhen the
apparatus was delivered. It maybe that the apparatus did not show
the 10percent reserve at delivery. If the apparatus
Pump ModelClearance Ring Inner Diameter (pressed
into pump body or pump head)IN (MM)
Impeller Hub OuterDiameter
PermissibleClearance
CBP 3.6312-3.6326(92.232-92.268)3.620-3.622
(91.948-91.999).009-.013
(.227-.330)
AP 4.770-4.777(121.158-121.336)4.760-4.758
(120.904-120.853).012-.017
(.305-.432)
Table 3-2: Impeller and Clearance Ring Diameters and Clearance
Values
-
Preventive Maintenance
Booster Pumps
Sec III- 7
GPM AT VARIOUS NOZZLE SIZESNOZZLE Nozzle SizePRESS 5/8 7/8 1" 1
1/8" 1 1 3/8
30 41 64 92 125 163 206 254 30835 44 69 99 135 176 222 275 33240
47 73 106 144 188 238 294 35545 50 78 112 153 199 252 311 37750 53
82 118 161 210 266 328 39755 55 86 124 169 220 279 344 41760 58 90
130 176 230 291 360 43562 58 91 132 179 234 296 366 44264 59 93 134
182 238 301 371 44966 60 94 136 185 241 305 377 45668 61 96 138 188
245 310 383 46370 62 97 140 190 248 315 388 47072 63 99 142 193 252
319 394 47774 64 100 144 196 255 323 399 48376 65 101 146 198 259
328 405 49078 66 103 148 201 262 332 410 49680 66 104 150 203 266
36 415 50285 68 107 154 210 274 347 428 51890 70 110 159 216 282
357 440 53395 72 113 163 222 289 366 452 547
100 74 116 167 228 297 376 464 562105 76 119 171 233 304 385 476
575110 78 122 175 239 311 394 487 589115 80 125 179 244 319 403 498
602120 81 127 183 249 325 412 509 615
GPM AT VARIOUS NOZZLE SIZESNOZZLE Nozzle SizePRESS 1 1 5/8 1 1
7/8 2 2 1/4" 2 " 3"
30 366 430 498 572 651 824 1017 146435 395 464 538 618 703 890
1098 158140 423 496 575 660 751 951 1174 169145 448 525 610 700 797
1009 1245 179350 473 555 643 738 840 1063 1313 189055 496 582 675
774 881 1115 1377 198260 518 608 705 809 920 1165 1438 207162 526
618 716 822 935 1184 1462 210564 535 628 728 835 950 1203 1485
213866 543 637 739 848 965 1222 1508 217268 551 647 750 861 980
1240 1531 220470 559 656 761 874 994 1258 1553 223672 567 666 772
886 1008 1276 1575 226874 575 675 783 898 1022 1293 1597 229976 583
684 793 910 1036 1311 1618 233078 590 693 803 922 1049 1328 1639
236180 598 702 814 934 1063 1345 1660 239185 616 723 839 963 1095
1386 1711 246590 634 744 863 991 1127 1427 1761 253695 651 765 887
1018 1158 1466 1809 2605
100 668 784 910 1044 1188 1504 1856 2673105 685 804 932 1070
1217 1541 1902 2739110 701 823 954 1095 1246 1577 1947 2803115 717
841 976 1120 1274 1613 1991 2867120 732 859 997 1144 1301 1647 2034
2928
Table 3-3
-
Booster Pumps
Sec III- 8 Preventive Maintenance
performance has dropped appreciablycompared to its original
performance, itneeds to be serviced. (Apparatus testresults should
be on file with the deliverydocuments. If not, they may be
obtainedfrom the apparatus manufacturer or from theoriginal
certifying authority.)
Worn Clearance Rings and Impeller Hubs
Because clearance ring replacement requirespump disassembly, it
is advisable to thoroughlycheck other possible causes of low
performancebefore assuming that clearance ring wear is atfault.
Clearance rings limit the internal bypass ofwater from the
discharge side of the pump backto the suction. The radial clearance
betweenthe impeller hub and the clearance rings is onlya few
thousandths of an inch when new. In clearwater, the clearance rings
continue to effectivelyseal for hundreds of hours of pumping. In
dirtyor sandy water, the impeller hub and clearancerings will wear
faster. The more wear, thegreater the bypass and lower
pumpperformance.
When new, the radial clearance between theimpeller hubs and the
clearance ring is from0.005 to 0.007 inch per side. Any increase
willallow more bypass and result in lowerperformance. It should not
be necessary toreplace clearance rings and impellers until
theaverage radial clearance reaches 0.015 to 0.020inch or more per
side, as measured withcalipers. Refer to Table 3-2.
If the clearance rings on the CBP pump showsignificant wear but
the impeller itself is withinthe size tolerance, "undersized "
clearance ringscan be installed to delay a complete rebuild.Contact
Customer Service at Hale Products andrefer to part 321-0070-01-0
for CBP
Often, replacement of the clearance rings willreduce the bypass
and restore the pump to nearoriginal performance. A complete
restoration
requires that the impellers also be replaced. SeeSection V for
maintenance and repairinformation if pump disassembly is
required.
EXTREME CONDITIONS
MAINTENANCE GUIDELINES
Freezing Weather
Drain the pump body and discharge valves. Ifthe gearbox is
equipped with a water coolingline, drain this line also. There
should be drainsfor the gauge lines, the cooling line to theengine,
and to the relief valve (if equipped). Allof these should be opened
until all water isdrained out, then close the drain valves.
In freezing weather, drain the pump as follows:
1. Open the discharge and suction valves,remove suction tube
caps and dischargevalve caps.
2. Open the pump body drain cocks and drainvalves
3. After the pump is completely drained replaceall caps and
close all valves.
Contaminated Water
After pumping salt water, contaminated water orfoam solution, or
if water containing sand orother foreign matter has been used,
connect thepump to a fresh water hydrant or other source offresh
clean water and flush the contaminantsout of the pump.
-
Troubleshooting Sec IV- 1
PUMP LOSES PRIME ORWILL NOT PRIME
NOTE: Weekly primingpump operation isrecommended to ensureproper
operation.
Electric Priming System No recommended enginespeed is required
to operatethe electric primer. However,1,000 engine RPM will
maintainthe electrical system whileproviding enough speed
forinitial pumping operation.
Defective Priming System Check the priming system byperforming a
Dry VacuumTest per NFPA standards. Ifthe pump holds vacuum,
butprimer pulls less than 22inches of vacuum, it couldindicate
excessive wear in theprimer.
DO NOT LEAVE THE CAB AFTER PUMP SHIFTING UNLESS THE SHIFT
INDICATOR LIGHT ISON, OR A SPEEDOMETER READING IS NOTED.
SECTION IV: TROUBLESHOOTING
Table 4-1 lists the symptoms of some common problems and
possiblecorrective measures. Before calling Hale or a Hale
authorized partsservice center for assistance, eliminate problem
causes using this guide.If the problem cannot be corrected, please
have the following informationready prior to calling the Hale
Customer Service Technician Departmentfor assistance. Customer
Service Number: 1-800-720-3473.
o Pump Model and Serial Numbero Observed symptoms and conditions
under which the symptoms occur.
NOTE: The location of the serial number will vary depending on
the pump model but it is generallydisplayed on the pump operator's
panel and/or the side of the gearbox.
PTO WILL NOT ENGAGE
TABLE 4-1. HALE PUMP TROUBLE ANALYSIS
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Consult PTO Manufacturer'sInstructions.
Faulty Wiring Verify the indicators areproperly functioning.
PUMP WILL NOT ENGAGE
Figure 4-1: Serial Plate
-
Sec IV- 2 Troubleshooting
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Suction lift too high Do not attempt lifts exceeding22 feet.
Restricted suction strainer Remove obstruction fromsuction hose
strainer.
Clean and tighten all suctionconnections. Check suctionhose and
hose gaskets forpossible defects.
Primer not operated longenough.
Proper priming proceduresshould be followed. Do notrelease the
primer controlbefore assuring a completeprime.
Suction Connections
PUMP LOSES PRIME ORWILL NOT PRIME (cont'd.)
Air Leaks Attempt to locate and correctair leaks using the
followingprocedure:
1. Perform dry vacuum test onpump per NFPA standards with22
inches minimum vacuumrequired with loss not toexceed 10 inches of
vacuum in5 minutes.
2. If a minimum of 22 inches ofvacuum cannot be achieved,the
priming device or systemmay be defective, or the leak istoo big for
the primer toovercome (such as an openvalve).
NOTICE: Do not run the primer over 45 seconds. If prime is not
achieved in 45 seconds, stop andlook for causes (air leaks or
blocked suction hose).
-
Troubleshooting Sec IV- 3
5. The suction side relief valvecan leak. Plug the valve
outletconnection and retest.
INSUFFICIENT PUMPCAPACITY
Insufficient engine power Engine power check or tune upmay be
required for peakengine and pump performance.
Refer to rotation symptomslater in this section.
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
PUMP LOSES PRIME ORWILL NOT PRIME (Cont'd.)
3. After priming, shut off theengine. Audible detection of aleak
is often possible.
4. Connect the suction hosefrom the hydrant or thedischarge of
another pumper topressurize the pump withwater, and look for
visibleleakage and correct. Apressure of 100 PSI (6.9 BAR)should be
sufficient. Do notexceed pressure limitations ofpump, accessories,
or pipingconnections.
Air Leaks (cont'd.)
Suction hose diameter is toosmall for the volume
beingdischarged
Use a larger suction hose.
Shorten total length byremoval of one length.
Reduce volume ofdischarge
Restriction in the suctionline at the strainer
Remove any debrisrestricting entrance ofwater at the
strainer.
Partial collapse of the liningin the suction hose
Damage to the outer lining mayallow air in between the outerand
inner linings causing apartial collapse. Replace thehose and
retest.
-
Sec IV- 4 Troubleshooting
Clean suction hose strainer ofobstruction and followrecommended
practices forlaying suction hose.
Blockage of suction hose entry
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Relief Valve improperly set If the relief valve control is
settoo low the relief valve willopen and bypass water. Resetthe
relief valve control per theprocedures in Section III. Otherbypass
lines (such as foamsystem or in-line valves) mayreduce pump
capacity orpressure.
INSUFFICIENT PUMPCAPACITY (cont'd.)
ENGINE SPEEDS TOO HIGHFOR REQUIRED CAPACITYOR PRESSURE
Truck transmission in wrongrange or gear
Verify the transmission is in thecorrect gear.
Lift too high, suction hose toosmall
Higher than normal lift (10 feet)will cause higher enginespeeds,
high vacuum andrough operation. Use largersuction hose. Bring the
pumpcloser to the water source.
Inner line of suction hose maycollapse when drafting and
isusually undetectable. Changethe suction hose on the pump;test for
comparison againstoriginal hose.
Defective suction hose
Pump is approachingcavitation.
Gate the discharge valves toallow pressure to increase.This will
reduce flow.Reduce the throttle openingto the original
pressuresetting.
-
Troubleshooting Sec IV- 5
RELIEF VALVE DOES NOTRELIEVE PRESSURE WHENVALVES ARE CLOSED
Incorrect setting of Control(PMD) Valve
Check and repeat properprocedures for setting reliefvalve
system. (See Section 3)
Relief Valve inoperative Refer to the relief valvemanual.
RELIEF VALVE DOES NOTRECOVER AND RETURN TOORIGINAL
PRESSURESETTING AFTER OPENINGVALVES
Dirt in system causingsticky or slow reaction
Refer to the relief valvemanual.
Clean the valve with a smallwire or straightened paper
clip.Refer to the relief valvemanual.
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Worn pump impeller(s) and / orclearance rings
Installation of new partsrequired.
Impeller blockage Blockage in the impeller canprevent loss of
both capacityand pressure. Back flushingthe pump from discharge
tosuction may free blockage.Removal of the pump headmay be required
(this isconsidered a major repair).
Blocked relief valve.
WATER IN PUMP GEARBOX Leak coming from above pump Check all
piping connectionsand tank overflow for possiblespillage falling
directly on tothe pump gearbox.
If mechanical seal is installed,there should be no leaks.Inspect
the oil seal andreplace if necessary.
Leaking Mechanical Seal
-
Sec IV- 6 Troubleshooting
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
DISCHARGE VALVESDIFFICULT TO OPERATE
Lack of lubrication Recommended weeklylubrication of discharge
andsuction valve, use anapproved lubricant. Refer tothe valve
manual for moreinformation.
Cavitation Troubleshooting
Water temperature too high. Reduce volume discharged bylowering
RPM or gating thedischarge valves.
Locate a source of coolerwater.
Pump is beginning tocavitate
Discharging more water thanthe pump is taking in.
Gate the discharge valves toreduce flow and
maintainpressure.
Increase the flow into the pumpwith more and/or larger
intakelines.
Air Leak
Locate and eliminate all airleaks during maintenance.
Verify air bleeder on thesuction tube is notopen.
Drafting too high
Locate the pump closer to thewater source.
Verify lift loss, hose friction,water temperature and otherlift
limiting factors are reducedor eliminated.
-
Troubleshooting Sec IV- 7
Figure 4-2 Impellers as installedon the 2CBP
CONDITION POSSIBLE CAUSE SUGGESTED CORRECTION
Rotation SymptomsIt is possible to reassemble the pump
incorrectly or withthe wrong parts. Always compare the replacement
partswith the original hardware. Contact customer service atHale
Products to answer questions or concerns.
Reduced pressure 60-100 psi.and reduced flow.
Wrong impeller installed Verify the new impeller vanesare
oriented the same as theold impeller before installing.See figure
4-3.
Impellers installed backwards(2CBP)
Verify the impellers are in thecorrect order. P/N 016-0280-00-0
is installed closest to thegearbox in an engine rotationapplication
and closest to thefront in an Opposite enginerotation
application.
Wrong Application The pump was installed on anapplication for
which it was notintended i.e. front mount vs.rear mount.
Figure 4-3 Engine rotation
-
Sec IV- 8 Troubleshooting
-
Maintenance and Repair
Booster Pumps
Sec V- 1
SECTION V MAINTENANCEAND REPAIR
OVERVIEW
This section describes the removal, inspection,and
re-installation (as required for maintenanceand repair) of all
booster pump components. Tocompletely disassemble the pump and
gearbox,follow the disassembly instructions in the orderwhich they
appear in this text. At any point in thedisassembly process, the
pump may bereassembled by following the instructionsbackwards
through this manual.
NOTE: Unless otherwise indicated, theseinstructions apply to all
Hale booster pumps.
General Repair Guidelines
1. Match mark or note the orientation ofcomponents before
disconnecting orremoving them.
2. Where grease is called for, use a LithiumBased Grease with 1
to 3% MolybdenumDisulfate. The following are examples ofapproved
greases:
o Dow Corning BR2-PLUSo Lubriplate Fiske #3000o Shell Super Duty
Greaseo Imperial #777o Mobil Grease Specialo Sunoco Moly #2EP
3. In the gearbox, use only oil with an API GL-5rating. Use SAE
EP-90, 80W-90 orsynthetic 75W-80 oil. (See Table 5-1 forgearbox oil
capacities.)
4. Before installing the mechanical seal, usethe alcohol swabs
provided by HaleProducts Inc. to clean all grease or oil fromthe
pump shaft and bearing housing.
5. Use only PAC-EASE Rubber LubricantEmulsion (or equal) on the
rubbermechanical seal parts to ease installation.
USE OF ANY OTHER LUBRICANT CANDAMAGE THE MECHANICAL SEAL
ANDSEAT.
6. Replacement steel fasteners, must be grade5, 360O nylon
patchlock fasteners. ApplyLoctite 242 (or equal) to all
threads.
7. Before working on the pump, disconnect thesuction and
discharge piping and drain thepump body. Disconnect cooling tubes
fromthe water manifold and pump as required.
8. Label and disconnect all wiring from thepump.
Cleaning and Inspection Guidelines
Wherever the procedures call for cleaning andinspection, these
guidelines should be followed:
1. Inspect all components for excessive orabnormal wear.
2. Wherever a requirement for new parts isindicated, obtain new
components from HaleProducts Inc.
3. Wherever procedures call for the removal ofgaskets, the
gasket should be replaced.Clean all gasket mating surfaces
beforeinstalling new gaskets.
4. Bearings and other components should becleaned using only
recommended solvents.
5. Bearings and seals should be inspectedwhenever the parts are
disassembled. Lookfor signs of excessive wear.
-
Sec V- 2 Maintenance and Repair
Booster Pumps
Bolt Size Material Maximum Torqueft-lb (n-m)
5/16-18 zinc-plated steel 17 (23)
5/16-18 zinc-plated steelw/360o nylon lock
19 (26)
5/16-18 silicon bronze 10.3 (14 )
3/8-16 zinc-plated steel 30 (41)
3/8-16zinc-plated steel
w/360o nylon lock 33 (45)
3/8-16 silicon bronze 18 (24 )
7/16-14 zinc-plated steel 50 (68 )
7/16-14zinc-plated steel
w/360o nylon lock 53 (72)
7/16-14 silicon bronze 29 (39)
Table 5-2: Torque Values
Pump ModelClearance Ring Inner Diameter (pressed into pump
body or pump head)In (mm)
Impeller Hub OuterDiameter
PermissibleClearance
CBP 3.6312-3.6326(92.232-92.268)3.620-3.622
(91.948-91.999).009-.013
(.227-.330)
AP 4.770-4.777(121.158-121.336)4.760-4.758
(120.904-120.853).012-.017
(.305-.432)
Table 5-3: Impeller and Clearance Ring Diameters and Clearance
Values
Model Gearbox Oil Capacity
AP 1 QTS. (1.66L)
CBP CBP2 & 3 = 1 QTS. (1.66L)CBP4 & 5 = 1 QT. (.95L)
2CBP2CBP2 & 3 = 1 QTS. (1.66L)
2CBP4 & 5 = 1 QT. (.95L)
Table 5-1: Oil Capacity Table
Figure 5-1 Measuring the Impellerand Clearance Ring
-
Maintenance and Repair
Booster Pumps
Sec V- 3
6. Replace any hardware that shows signs ofexcessive wear.
7. When inspecting the impellers and clear-ance rings for wear,
measure the impellerhub diameter and the inner diameter of
theclearance ring. Compare these measure-ments to data in Table
5-3. If measure-ments indicate, obtain replacement clear-ance rings
and impeller.
NOTE: If either the impeller hub or clearancerings are out of
tolerance, both rings and theimpeller must be replaced as well as
themechanical seal.
Recommended Cleaners
Hale recommends:
o Safety Kleen
o Stoddard Solvent
Tools Required
Lifting gear-lever hoist or chain hoist, andshort choker
Ball peen hammer Center punch Drift punch Allen wrenches Strap
wrench Snap Ring Pliers Pry bars (2) Ratchets and wrenches for
disassembly Torque wrench, capable of 40, 65, and 135
ft-lb (54, 88, and 183 N-m) Pan (to catch drip oil)
Disposable-rags Oil dry Wood Wedges Bearing Puller Pusher tube (a
small section of PVC tubing
to fit over the shaft)
PUMP COMPONENTS
Pump and Gearbox Assembly
Read all the instructions before beginning anyrepair.
THE PUMP AND GEARBOX ASSEMBLIESWEIGH APPROXIMATELY 250 LBS (113
KG).USE PROPER LIFTING DEVICE WHENREMOVING OR INSTALLING PUMP
ANDGEARBOX ASSEMBLY.
NOTE: These procedures refer to Figures 5-2and 5-3. Please
review the General Repair andCleaning and Inspection Guidelines on
page 37before beginning these procedures.
Remove the Pump from the Apparatus
1. Park the vehicle on a level surface. Set theparking brake and
chock the front and rearwheels.
2. Place apparatus out of service inaccordance with departmental
procedures.
3. Obtain access to the pump and gearbox.Match mark or tag all
connections beforeremoval.
4. Remove drain plugs and drain the pump andpiping. Disconnect
suction and dischargepiping from the pump.
5. Remove the magnetic oil-drain plug (seeFigure 5-2). Drain the
gearbox oil into asuitable container. Examine the oil forincluded
water (water turns the oil a milkycolor or settles in the bottom of
the oil) andproperly dispose of the oil.
6. Disconnect the drive shaft from the gearbox.
-
Sec V- 4 Maintenance and Repair
Booster Pumps
7. Disconnect airlines, electrical switches, andthe tachometer
cable as required.
8. Attach a proper lifting device beforeloosening or removing
mounting brackets.
9. Disconnect mounting brackets to removethe pump and gearbox
assembly.
10. Place the pump and gearbox assembly on astable work stand.
The air vent and gearboxcover are exposed. This will provide
easyand safe access to the internal components.
REINSTALL PUMP ON APPARATUS
After completing repairs and /or maintenance,reinstall the pump
and gearbox assembly.
1. Place the pump and gearbox assembly on astable platform.
Attach a proper liftingdevice.
2. Lift the pump and gearbox assembly intoposition on the
equipment. Connect the
mounting brackets using the properfasteners. Torque the
fasteners to valuesprovided in Table 5-3.
3. Connect the drive shaft to the gearbox.Apply Loctite to the
fasteners and torqueto PTO manufacturer's specifications.
4. Connect any electrical switches, airlines andtachometer cable
if appropriate.
5. Install the magnetic oil-drain plug.
6. Fill the gearbox to the level of the oil plug.Use only oil
with an API GL-5 rating. UseSAE EP-90, 80W-90 or synthetic
75W-80oil. See Table 5-1 for approximate gearboxoil capacity.
7. Reconnect the suction and discharge pipingto the pump.
8. Test the pump for proper operation, note anyleaks.
9. Return the apparatus to normal operation.
Figure 5-3: CBP Pump and GearboxAssembly with Gearbox
CoverFigure 5-2: AP Pump and Gearbox
Assembly with Optional Cooler
-
Maintenance and Repair
Booster Pumps
Sec V- 5
AP PUMP DISASSEMBLY
AP Pump Body
The pump body can be removed from thegearbox assembly providing
access to theinternal parts without disconnecting the
driveunit.
Remove AP Pump Body
1. Disconnect the suction, discharge, coolinglines, and any
electrical wiring. Disconnectmounting brackets as required. Match
markthe pump body and pump head to ensureproper alignment during
reassembly.
2. Remove the 7/16 - 14 X 1" cap screws thathold the pump body
assembly to the pumphead.
3. Remove the pump body from the pumphead, do not damage the
brass clearancerings or impeller.
Figure 5-4: AP Pump andGearbox Assembly
4. Remove all remaining gasket material fromthe mating surfaces
of the pump body andpump head.
Install the Pump body
1. Use a press to install the clearance ring inthe pump
body.
2. Apply a small amount of grease to thegasket and align on the
pump body.
3. Install the pump body onto the pump head,do not damage the
clearance rings orimpeller.
4. Apply Loctite 242 (or equal) to the threadsand install the
7/16-14 UNC x 1 cap screwsthat hold the pump body to the pump
head.Refer to Table 5-2 for recommended torquevalues for fastener
size and material.
5. Reconnect all piping and tubing.
6. Return the apparatus to service.
AP IMPELLER AND MECHANICAL SEAL
Remove AP Impeller
1. Remove the pump body as described above.
2. Remove the cotter pin that secures theimpeller nut.
3. Hold the impeller with a strap wrench, andremove the impeller
nut.
4. To avoid warping the impeller, use wedgesand a proper puller
t